BOILER NG CALCULATION

Component Vol% Mol.Wt. XiMi

Methane 98.03 16 15.6848
Ethane 0.69 30 0.207
Propane 0.03 44 0.0132
Nitrogen 1.25 28 0.35
Total Mol. Wt. 16.255 kg/kmol
345.4321747 kmol/hr

Total fuel flow rate to no of burners in service 5615 kg/hr

PV = nRT
where R 8314 Pa*M3/Kg.K
T1 300.78 K
P1 3500000 Pa

so V1 863817030.2
V1 246.8048658 M3/hr

P2 1 atm 101325 Pa
T2 0 °C 273 K

P1*V1/T1 P2*V2/T2
V2 P1*V1*T2/P2*T1
V2 7737.823898 NM3/hr
 REFORMER NG CALCULATION

Component Vol% Mol.Wt. XiMi kmol/h

Methane 98.03 16 15.68469101 223.35
Ethane 0.69 30 0.206724017 1.57
Propane 0.03072 44 0.013518258 0.07
Nitrogen 1.25 28 0.350245787 2.85
227.84
16.3 kg/kmol
227.7914 kmol/hr

Total fuel flow rate to no of burners in service 3713 kg/hr

PV = nRT
where R 8314 Pa*M3/Kg.K
T1 313 K
P1 3000000 Pa

so V1 197.5925
V1 197.5925 m3/hr

P2 1 atm 101325 Pa
T2 0 °C 273 K

P1*V1/T1 P2*V2/T2
V2 P1*V1*T2/P2*T1
V2 5102.622 NM3/hr
 EFFICIENCY & TOTAL AIR FLOW OF BOILER
Boiler Efficiency = (Heat Output/Heat Input)*100
Q * (Hg - Hf)
Boiler efficiency = * 100
q * GCV

Where
Hg Enthalpy of saturated steam in kcal/kg of steam
Hf Enthalpy of feed water in kcal/kg of water

NG flow 7737.8239 NM3/hr

NG density 0.727 Kg/NM3
5625.39798 Kg/hr
12404.0025 lb/hr
5.62539798 T/hr

DATA :
Quantity of steam generated Q 100 TPH
Steam Pressure P 35 Bar
Steam Temperature T 250 °C
Quantity of NG consumed q 5.625397975 TPH
Feed water temperature 105 °C
GCV of NG 12966 Kcal/Kg
Enthalpy of steam at 35 Bar Hg 670 Kcal/Kg
Enthalpy of feed water Hf 105 Kcal/Kg

Boiler Efficiency = 77.4620842 %

CH4 C2H6 C3H8 H2S (10ppm) Total

Mol% 98.03 0.69 0.03 0.001
C 73.5225 0.552 0.024545 74.09905
H 24.5075 0.138 0.005455 5.88235E-05 24.65101
S 0.000941176 0.000941
98.751

Theoritical air requirement [11.6*C + (34.8*(H2- (O2/8))+ (4.35*S)]/100

1717.408
17.17408 kg/kg of fuel
96611.05 Kg/hr

Excess air supplied [O2% / (21 - O2%)]*100

Assume 2% of oxygen in flue gas.

 O2 2%

Excess air supplied (EA) 10.52632 %

Actual mass of air supplied [1 + (EA/100)] * Theoritical air

1.105263 * Theoritical air
18.98188 kg/kg of fuel
Actual mass of air supplied 106781 kg/hr

As per thermax total air consumption. 103119 Kg/hr

kg/kg of fuel
 Stack Losses for NG
Component %
C 0.72
H 0.238
N2 0.031
O2 0.011

O2 dry O2 wet* (1.222 - 0.012*O2wet)

O2 dry 1.196
O2 dry 2.392 %

CO2 dry 11.368 - (0.556*O2 dry)

CO2 dry 10.03005 %

Dry flue gas [((11*CO2 dry) + (8*O2dry) + (7*N2))*C]/(3*CO2 dry)

N2 100 - O2 dry - CO2 dry

87.57795 %

Dry flue gas 534.608778

17.7669066 lb/lb of fuel

Excess Air 100 * O2 dry / [(0.2682*N2) - (O2 dry)]

239.2
21.09641
Excess Air 11.33842 %

Dry flue gas loss (LDG) DG* Cp * (FGT - CAT)*100 * HHV

2.14133896 %

Loss due to moisture from combustion of hydrogen

LH ((9*H2*[(Enthalpy of vapor at 1 PSIa & FGT)- (Enthalpy of liquid at CAT)]*100 /

Hg 1055 + 0.467*FGT
1125.05 BTU/lb
Hf CAT - 32
3 BTU/lb

LH 240343.11
10.4953323 %

Stack losses
Ls LDG + Lh
12.6366713 %
(7*N2))*C]/(3*CO2 dry)

HHV 22900 BTU/lb

53261.68 kj/kg
12720.73 kcal/kg

t 1 PSIa & FGT)- (Enthalpy of liquid at CAT)]*100 / HHV

 REQUIRED NG FLOW TO BOILER
WATER PREHEAT :
Economiser inlet 105 °C
Economiser outlet 160 °C
Flowrate 100000 kg/hr
Heat capacity (Cp) 1 Kcal/kg°C

Q M*Cp*(To - Ti)
Q 5500000 Kcal/hr ------------------------------- (1)

FLUE GAS :
Flue gas outlet temp 150 °C
302 °F
Flue gas inlet temp 35 °C
95 °F
Flue gas flow 17 lb/lb of fuel
210868 lb/hr
Heat capacity (Cp) 0.24 BTU/lb°F

Q M*Cp*(To - Ti)
Q 10475924.38 BTU/hr
Q 2639622.695 Kcal/hr ------------------------------- (2)

STEAM GENERATION :
Q M*Cp*(To - Ti) + mλ
The latent heat of vaporization for water is 539.6 kcal/kg

9000000 53960000
Q 62960000 kcal/hr ------------------------------- (3)

BLOWDOWN LOSSES :
Blowdown (contineous) 3000 Kg/hr
(intermediate) 1000 Kg/hr
Blowdown inlet temp 100 °C
Blowdown outlet temp 35 °C

Q M*Cp*(To - Ti)
Q 260000 Kcal/hr ------------------------------- (4)

Total heat 71359622.69 Kcal/hr

GCV 12966 Kcal/kg

NG Flow 5504 Kg/hr